US2006079615A1PendingUtilityA1

Stabilized blends of polycarbonate with emulsion derived polymers

42
Assignee: DERUDDER JAMES LPriority: Oct 12, 2004Filed: Oct 12, 2004Published: Apr 13, 2006
Est. expiryOct 12, 2024(expired)· nominal 20-yr term from priority
Inventors:James L. DerudderRobert R. Gallucci
C08L 25/12C08L 25/08C08L 55/02C08L 33/08C08L 51/003C08L 51/04C08K 3/26C08L 69/00C08L 33/10C08K 5/524
42
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Claims

Abstract

Blends of polycarbonate with emulsion polymerization derived polymers, such as ABS, ASA and MBS, may be stabilized against loss of properties due to the action of water, by addition of calcined alumino magnesium carbonate.

Claims

exact text as granted — not AI-modified
1 ) A composition with improved hydrolytic stability comprising a mixture of polycarbonate, an emulsion based polymer, and calcined alumino magnesium carbonate in an amount effective to provide improved hydrolytic stability to the composition.  
     
     
         2 ) The composition of claim I wherein the calcined alumino magnesium carbonate is a calcined hydrotalcite.  
     
     
         3 ) The composition of  claim 1  wherein the amount of calcined alumino magnesium carbonate is from 0.005 to 5.0 wt % of the polycarbonate and emulsion based polymer composition.  
     
     
         4 ) The composition of  claim 1  wherein the calcined alumino magnesium carbonate has a magnesium oxide to aluminum oxide mole ratio of about 1.0 to 5.0.  
     
     
         5 ) The composition of  claim 1  wherein the alumino magnesium carbonate has an average particle size of less than or equal to about 10 microns.  
     
     
         6 ) The composition of  claim 1  wherein the calcined alumino magnesium carbonate has less than about 30 ppm of elements selected from the group consisting of: 
 mercury, lead, cadmium, arsenic, bismuth and mixtures thereof.    
     
     
         7 ) The composition of  claim 1  wherein the emulsion based polymer is at least a member selected from the group consisting of poly acrylonitrile butadiene styrene, poly acrylonitrile styrene (meth)acrylate, poly alkyl(meth)acrylate butadiene styrene, poly alky(meth)acrylates, poly styrene acrylonitrile, poly styrene maleic anhydride, poly acrylonitrile butadiene acrylate, and combinations thereof.  
     
     
         8 ) The composition of  claim 1  wherein the emulsion based polymer is coagulated with acid.  
     
     
         9 ) The composition of  claim 8  wherein the acid has pH of less than about 5.0.  
     
     
         10 ) The composition of  claim 1  wherein the ratio of polycarbonate to emulsion based polymer is about 20:80 to 95:5.  
     
     
         11 ) The composition of  claim 10  wherein the ratio of polycarbonate to emulsion based polymer is a mixture of from 45-90 wt % polycarbonate, 0-30 wt % polystyrene acrylonitrile, 5-35% poly acrylonitrile butadiene styrene and 0.05 to 0.5 wt % calcined hydrotalcite.  
     
     
         12 ) The composition of  claim 11  wherein the polystyrene acrylonitrile has 20-40 wt % units derived by polymerization of acrylonitrile.  
     
     
         13 ) The composition of  claim 1  wherein the polycarbonate has a weight average molecular weight of 15,000-80,000.  
     
     
         14 ) The composition of  claim 1  further comprising the addition of a phosphite stabilizer.  
     
     
         15 ) The composition of  claim 1  wherein the blends of polycarbonate with emulsion derived vinyl polymers and calcined alumino magnesium carbonate retain at least about 50% of the initial tensile strength of the composition, as measured by IS0527, after exposure to about 95% relative humidity for about 500 hours at about 90° C.  
     
     
         16 ) The composition of  claim 15  wherein the initial tensile strength is from about 30 to 70 Mpa.  
     
     
         17 ) The composition of  claim 1  wherein the stabilized polycarbonate, emulsion polymer and calcined alumino magnesium carbonate blends have a HDT, as measured at 1.8 Mpa, by ISO method 75 Af, from 100 to 150° C.  
     
     
         18 ) A composition with improved hydrolytic stability comprising blends of polycarbonate with emulsion derived vinyl polymers and calcined alumino magnesium carbonate which retain at least about 50% of the initial Izod impact strength of the composition, as measured by IS0180, after exposure to about 95% relative humidity for about 500 hours at about 90° C.  
     
     
         19 ) The composition of  claim 18  wherein the initial Izod impact strength of the stabilized polycarbonate, emulsion polymer and calcined alumino magnesium carbonate blends is greater than about 40 kJ/m2.  
     
     
         20 ) A composition with improved hydrolytic stability comprising blends of 45-90 wt % polycarbonate with 10-45 wt % emulsion derived acrylonitrile butadiene styrene polymers and 0.001-1.0 wt % calcined alumino magnesium carbonate which retain at least about 50% of the initial tensile strength of the composition, as measured by IS0527, after exposure to about 95% relative humidity for about 500 hours at about 90° C.  
     
     
         21 ) A process to improve the stability of blends of polycarbonate with emulsion derived vinyl polymers comprising the addition of sufficient calcined alumino magnesium carbonate to retain at least about 50% of the initial tensile strength of the composition, as measured by IS0527, after exposure to about 95% relative humidity for about 500 hours at about 90° C.  
     
     
         22 ) The process of  claim 21  wherein the sufficient amount of calcined alumino magnesium carbonate is from 0.005 to 5.0 wt % of the polycarbonate and emulsion based polymer composition.  
     
     
         23 ) The process of  claim 21  wherein the initial tensile strength is from about 30 to 70 Mpa.  
     
     
         24 ) The process of  claim 21  wherein the calcined alumino magnesium carbonate has a magnesium oxide to aluminum oxide mole ratio of about 1.0 to 5.0.  
     
     
         25 ) The process of  claim 21  wherein the calcined alumino magnesium carbonate has an average particle size of less than or equal to about 10 microns.  
     
     
         26 ) The process of  claim 21  wherein the calcined alumino magnesium carbonate has less than about 30 ppm of elements selected from the group consisting of: 
 mercury, lead, cadmium, arsenic, bismuth, and mixtures thereof.    
     
     
         27 ) The process of  claim 21  wherein the emulsion based polymer is at least a member selected from the group consisting of the group consisting of poly acrylonitrile butadiene styrene, poly acrylonitrile styrene (meth)acrylate, poly alkyl(meth)acrylate butadiene styrene, poly alky(meth)acrylates, poly styrene acrylonitrile, poly styrene maleic anhydride, poly acrylonitrile butadiene acrylate and combinations thereof.  
     
     
         28 ) The process of  claim 21  wherein the emulsion based polymer is coagulated with acid.  
     
     
         29 ) The process of  claim 28  wherein the acid has pH of less than about 5.0.  
     
     
         30 ) The process of  claim 21  wherein the ratio of polycarbonate to emulsion based polymer is about 20:80 to 95:5.  
     
     
         31 ) The process of  claim 30  wherein the ratio of polycarbonate to emulsion based polymer is a mixture of from 45-90 wt % polycarbonate, 0-30 wt % polystyrene acrylonitrile, 5-35% poly acrylonitrile butadiene styrene and 0.05 to 0.5 wt % calcined hydrotalcite.  
     
     
         32 ) The process of  claim 31  wherein the polystyrene acrylonitrile has 20-40 wt % units derived by polymerization of acrylonitrile.  
     
     
         33 ) The process of  claim 21  wherein the stabilized polycarbonate, emulsion polymer, calcined alumino magnesium carbonate blends have a HDT, as measured at 1.8 Mpa, by ISO method 75 Af, from 100 to 150° C.  
     
     
         34 ) The process of  claim 21  wherein the polycarbonate has a weight average molecular weight of 15,000-80,000.  
     
     
         35 ) The process of  claim 21  further comprising the addition of a phosphite stabilizer.  
     
     
         36 ) The process of  claim 21  where the calcined alumino magnesium carbonate is a calcined hydrotalcite.  
     
     
         37 ) A composition made by the process of  claim 21 .  
     
     
         38 ) A molded article made by the composition of  claim 37 .  
     
     
         39 ) A process to improve the stability of blends of polycarbonate with emulsion derived vinyl polymers comprising the addition of sufficient calcined alumino magnesium carbonate to retain at least about 50% of the initial Izod impact strength of the composition, as measured by IS0180, after exposure to about 95% relative humidity for about 500 hours at about 90° C.  
     
     
         40 ) The process of  claim 39  wherein the initial Izod impact strength of the stabilized polycarbonate, emulsion polymer, calcined alumino magnesium carbonate blends is greater than about 40 kJ/m2.  
     
     
         41 ) A process to improve the stability of blends of 45-90 wt % polycarbonate with 10-45 wt % emulsion derived acrylonitrile butadiene styrene polymers comprising the addition of 0.001-1.0 wt % calcined alumino magnesium carbonate to retain at least about 50% of the initial tensile strength of the composition, as measured by IS0527, after exposure to about 95% relative humidity for about 500 hours at about 90° C.  
     
     
         42 ) A molded article made by the composition of  claim 1.

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